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Selective Laser Melting (SLM) has become one of the most promising technologies in Metal Additive Manufacturing (MAM), which is a complex dynamic non-equilibrium process involving heat transfer, melting, phase transition, vaporization and mass transfer. The characteristics of the molten pool (structure, temperature flow and velocity flow) have a decisive influence on the final forming quality of SLM. In this study, both numerical simulation and experiments were employed to study molten pool structure, temperature flow and velocity field in Selective Laser Melting AlCu5MnCdVA alloy. The results showed the structure of molten pool showed different forms (deep-concave structure, double-concave structure, plane structure, protruding structure and ideal planar structure), and the size of the molten pool was approximately 132  μ m × 107  μ m × 50  μ m: in the early stage, molten pool was in a state of deep-concave shape with a depth of 15  μ m due to multiple driving forces, while a protruding shape with a height of 10  μ m duo to tension gradient in the later stages of forming. The metal flow inside the molten pool was mainly driven by laser impact force, metal liquid gravity, surface tension and recoil pressure. For AlCu5MnCdVA alloy, metal liquid solidification speed was extremely fast (3.5 × 10 −4  S), the heating rate and cooling rate reached 6.5 × 10 7  K S −1  and 1.6 × 10 6  K S −1 , respectively. Choosing surface roughness as a visual standard, low-laser energy AlCu5MnCdVA alloy optimum process parameters window was obtained by numerical simulation: laser power 250 W, hatching space 0.11 mm, layer thickness 0.03 mm, laser scanning velocity 1.5 m s −1 . In addition, compared with experimental printing and numerical simulation, the width of the molten pool was about 205 um and about 210 um, respectively, and overlapping between two adjacent molten tracks was all about 65 um. The results showed that the numerical simulation results were basically consistent with the experimental print results, which proved the correctness of the numerical simulation model.

Molten pool structure, temperature and velocity flow in selective laser melting AlCu5MnCdVA alloy